FRED LEVKO

2663 Valley Road

Wildwood, Missouri 63005
Home: (636) 256 9549 Cell: (314) 249-7984 Fax: (425) 871-0125
E-mail: fle277b6@westpost.net LinkedIn Profile: http://www.linkedin.com/in/fredl
evko
CAREER SUMMARY
LEAN PRACTITIONER ACHIEVING PROSPEROUS PROCESS IMPROVEMENT to successfully imple
mented and sustained Lean Operating Systems at 30 global sites for industrial co
ntrol, automotive, charitable, and healthcare operations. Engaged Senior Managem
ent to practice Lean and lead the transformation process. Accomplished engineer
for project management, product design, manufacturing, and transactional improv
ements. Awarded eleven patents. Hands-on, creative problem solver working with
the shopfloor on kaizen teams to reduce waste and increase value.
CERTIFICATION
Ford Motor Company Lean Certification, Emerson Electric Lean Sponsor,
Six Sigma Green Belt
EDUCATION
MBA, DePaul University, Chicago, IL
BSEE, Oakland University, Rochester, MI
Mentored 6 years by Lean Sensei former General Manager Toyota Georgetown facilit
y
PROFESSIONAL EXPERIENCE
LEAN CONSULTING GROUP, LLC St. Louis, MO
Principal Consultant 2009-Present
Develop lean manufacturing capability at multiple clients in Manufacturing and H
ealthcare at multiple domestic sites.
* Coordinated and delivered Leadership training to Senior Managers for transform
ing culture to a Lean Management System.
* Initiated and deployed projects in corporate office to improve supply chain an
d treasury performance
* Created team work environment to support hospital site improvement projects th
at reduced denied claims by 30% and increased patient throughput by 20%
* Developed systems to controlled documentation for project site training activi
ty
* Lead kaizen team to reduce product defects by 30% and reduce order lead time b
y one week
* Trained 150 plant staff on problem-solving and visual management methods that
reduced OSHA recordable and product line efficiency by 35%
* Collaborated with senior leadership to transform manufacturing to a lean opera
tion system, which reduce defects to 150ppm and improves employee communications
for safety
* Implemented food distribution method reducing lead-time to 3 days from 3 weeks

FRED LEVKO (636-256-9549) Page Two

EMERSON ELECTRIC, Process Management--Valve Automation St. Louis, MO
Manager, Operations Excellence 2006 - 2009
Articulate and executed a coherent roadmap for a Global Lean System at twelve s
ites in North America, Europe, Africa, and Asia. Reported to Executive Vice Pres
ident of Operations.
* Achieved $2 million annual cost savings by applying Lean activities on the sho
pfloor at four domestic sites
* Improved supplier quality performance through on-site engagement with three in
ternational and two domestic suppliers, which achieved 25% lead-time improvement
and improved quality to less than 1,000 ppm.
* Consolidated three individual global reports on key performance metrics into a
single reporting process for Senior Management presentation, which reduced lead
time, labor and errors by 75%
* Lead kaizen teams that achieved 30% improvements, which reduced order-to-cash
lead-time by four weeks and reduced new-hire fulfillment by 50 days.
* Conducted training sessions on Lean fundamentals and Process Mapping/Value Str
eam with ten team at five global sites
* Mentored Lean Coordinators at eight global sites to promote local site project
s
SIEGEL-ROBERT, INC. , Corporate St. Louis, MO
Manager, Corporate Lean Enterprise 2000 - 2006
Transitioned to Lean Operating Systems at 13 traditional domestic and internatio
nal manufacturing facilities. Reported to the Chief Operating Officer.
* Achieved turned around of bottom-line $10 million loss to $20 million gain via
scrap reductions, increased inventory turns, and Lean initiative applications w
ith kaizen
* Lead team that documented and implemented a systematic Lean implementation pro
cess modeled on Toyota Production System (TPS)
* Applied Policy Deployment (True North, Hoshin Kanri) to align plant level proj
ects with corporate strategic goals specifically to evaluate and integrate acqu
isition with Lean Operating System
* Developed balanced scorecard metrics to identify gaps for restoring deficient
performance and define corporate incentive compensation
Value Analysis & Value Engineering Manager 1991 - 2000
Implemented Value Management programs to satisfy customers' requirements. Repor
ted to the Executive Vice President of Engineering.
* Executed a Value Management program at six plant locations by designing organ
izational structure, training methods and materials with a system of continuous
feedback to achieve $5.5 million annual savings
* Implemented Continuous Process Improvement methods and guided Cost Accounting
(Activity Based Accounting (ABC)/Lean practices) in a plant to yield 3:1 saving
s for the staff time investment with minimal capital investment
* Redesigned products to improve assembly methods and resolve performance proble
ms thereby increasing production yield and reducing field failures by 30%.
TECHNICAL SKILLS
Plastic Injection Molded and Metal Component Design. Applied A3, Kaizen, TPM, Ka
nban, Poke Yoke, Jidoka (Quality at the Source), Standard Work, and SMED for con
tinuous improvement. Proficient trainer for Change Management, Workplace Organi
zation/Safety, Visual Management, and Value Stream Mapping. Experience user of M
icrosoft Applications: PowerPoint, Access, Word, Excel, Visio, Project